The document provides guidance on overhead crane safety and regulations. It discusses employer and employee duties to maintain health and safety. Regulations covered include PUWER, LOLER, and requirements for inspections, risk assessments, training, markings, planning, and examinations. Specific lifting equipment is explained like beams, slings, hooks, and magnetic accessories. Factors that impact magnetic lifts like load composition and surface conditions are also summarized.

1. Overhead Crane Awareness/Training
Instructor - Simon Slater

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SAFETY AND WELFARE INFORMATION
Fire Alarm, Tests and Evacuation
Welfare Facilities
Breaks and Refreshments
Phones

4. 4
The Health and Safety
at Work Act
1974

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6. Employer’s Duties to their Employee’s
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Section 2
2a To provide safe plant and safe systems of work.
2b Safety and absence of risks in connection with use,
handling, storage and transportation of articles and
substances.
2c Provide adequate information, instruction, training and supervision.
2d Safe place of work, and access to egress from the workplace.
2e Safe working environment.

7. Employee’s Duties
7
Section 7
a Duty to take reasonable care of self and other
persons who may be affected by acts or omissions
b Duty to co-operate with employer and other
persons in ALL matters concerning Health and
Safety.
Section 8
Duty not to interfere with or recklessly misuse
anything provided in the interests of
health / safety / welfare.

8. Provision and Use of Work Equipment Regulations 1998
(PUWER)
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Regulation 5
5 (1):Every employer shall ensure that work
equipment is maintained in an efficient state,
in efficient working order and in good repair.
(2):Every employer shall ensure where any
machinery has a maintenance log, the log
is kept up to date.

9. PUWER 1998
9
Regulation 9
9(1) Every employer shall ensure that all persons who
use work equipment have received adequate training for
purposes of health and safety, including training in the
methods which may be adopted when using the work
equipment, any risks which such use may entail and
precautions to be taken.
9(2) Every employer shall ensure that any of his
employees who supervises or manages the use of work
equipment have received adequate training for purposes
of health and safety, including training in the methods
which may be adopted when using the work equipment,
any risks which such use may entail and precautions to be
taken.

10. Lifting Operations And Lifting Equipment
Regulations
• LOLER regulations came in to force in 1998.
• They cover all operations and equipment which
involve lifting people and goods at work.
• They cover such equipment as cranes, ropes, slings,
hooks, shackles, eyebolts, rope and pulley systems
and forklifts.
• They also cover second hand and leased equipment.
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11. Marking(regulation 7)
• Equipment, including accessories, must be marked with the safe
working load and I.D number.
• Equipment for lifting persons must be clearly indicate the maximum
to be carried.
• Equipment not intended for lifting persons but which could be used
in error must be clearly marked that it is not designed for lifting
persons.
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12. Planning And Supervision(regulation 8)
• Employers must ensure that every operation with equipment involving
the lifting or lowering of a load must be properly planned by a
competent person.
• APPROPRIATELY supervised and carried out in a safe manner.
• The planner should have adequate practical and theoretical knowledge
and experience.
• The plan must address the risks identified by the risk assessment and
propose APPROPRIATE control measures.
• If an operator cannot observe the full path of a load, the employer must
provide person(s) able to guide him.
• APPROPRIATE measures must be taken to ensure that loads are
attached, detached and secured SAFELY.
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13. Examinations(regulation 9)
• Employers must ensure that equipment is thoroughly examined before it is put
into service for the first time and after any significant change that affects its
operation.
• This should be carried out by an independent examiner which for your company
is Zurich.
• Where safety depends on the installation conditions, it must be thoroughly
examined on each occasion after installation or assembly and before use.
• Equipment must be thoroughly inspected at least every 6 months for
accessories, at least every 12 months if used for other purposes or according to a
scheme devised by the examiner.
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WHAT IS THE PURPOSE OF A RISK ASSESSMENT?
TO IDENTIFY ALL RISKS AND PROPOSE APPROPIATE CONTROL MEASURES
WHAT IS THE PURPOSE OF A STANDARD OPERATION?
A DOCUMENT THAT GIVES SPECIFIC INSTRUCTIONS ON HOW TO CARRY OUT A TASK SAFELY.
AFTER READING THE ABOVE DOCUMENTS AND RECEIVING TRAINING, ANY DEVIATION FROM
THE RULE COULD RESULT IN DISCIPLINARY PROCEDURE. FROM A VERBAL WARNING, WRITTEN
WARNING, DISMISSAL OR EVEN PROSECUTION

15. Girder Rail And Swing Crane

16. LIFTING BEAMS
• LIFTING BEAMS FOR LONG
LENGTHS
• MANY VARIOUS TYPES AND
USES
• CAN BE JOB SPECIFIC
• UNDERSTAND THE
EQUIPMENT BEFORE USE
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17. LIFTING BEAMS
• LIFTING BEAMS COME IN
ALL SORTS OF DIFFERENT
SHAPES AND SIZES
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18. Pendent Operated Cranes

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CHAIN SLING WIRE ROPE
FIBRE SLING EYEBOLTS
SHACKLES CLAMPS
LIFTING BEAMS

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MASTER LINK ASSEMBLY
COMPONENT CONNECTOR
SHORTENING CLUTCH
SAFETY HOOK

21. 21

22. SLING COLOUR CHART
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23. Magnetic Lifting Accessories
 Potential dangers from the use of magnetic lifting equipment…
 Factors, including load configuration, which may cause equipment or lifting
operation failure and how to avoid them
 Principles for selecting the right equipment
 Limitations on the use of the equipment including the ‘de-rating’ of the SWL
depending on the thickness and type of material (eg bar, plate) calculated from
the lifting tables supplied by the manufacturer
 Arrangements for planning and carrying out safe lifting operations, including safe
systems of work
 Specific instructions on safe use issued by the manufacturer/supplier
 Location and operation of the equipment controls
 Arrangements for pre-use, in-service inspection and maintenance including
reporting of any defects

24. Magnetic Lifting Accessories The principal safety hazard associated with the use of magnets is from
falling material. People, plant, equipment, and services in the area of
operation could be at risk from being struck by material which becomes
detached from the magnet e.g. due to failure of the lifting device
following loss of power, or due to incorrect application or operation.
 A potential health risk to people working in the vicinity of these magnetic
lifting devices is from the electromagnetic field (EMF) around the magnet. It is
thought that this may interfere with the operation of implanted active body
implants, such as heart pacemakers or insulin pumps. EMFs can also interfere
with communication and control systems/equipment which could be safety
related and therefore, create consequent risks which should also be assessed.
 Magnetic lifting devices should not be treated as 'general purpose' pieces of
lifting gear as they have to be designed to suit particular types of loads and
environments. Users should seek advice from the equipment manufacturer on
the suitability of an existing device for all new applications. Please seek advice
from technical to clarify the suitability of the lifting gear for each job.

25. Magnetic Lifting Accessories Take in to consideration…
 Magnetic properties of the load - Magnet lifting is not appropriate for all steels.
For example, some stainless steels are not magnetic and other types are only
partially magnetic. When handling mixed steel types, it should be recognised that
non/partially magnetic items are likely to fall away if magnetised pieces
supporting them move.
 Load weight, thickness, shape and area in contact with magnet - The
surface area of the load and the proportion of the magnet face in contact with it
will dictate the number and size of magnets required for safe handling almost as
much as the weight and thickness of the load. For example, a billet may only
require a single magnet, whereas a thin plate section of equal weight may require
a multiple arrangement of magnets.
 Surface profile of materials to be lifted - Where the surface is non-uniform e.g.
corrugated, embossed or perforated sheet, flat lifting magnets can be used but
must be rated according to the percentage of the load which actually contacts the
magnet face.
 Composition of the load – A porous load or a load with an internal void may not
adhere as well as a solid load

26. Magnetic Lifting Accessories
 Lifting of multiple loads - Multiple loads can include several sheets or plates. Part of
the load may fall off, even though the nominal SWL has not been exceeded.
 Stiffness or flexibility of the load - Droop or overhang at the ends of a flexible load
e.g. long bar, flat or thin sheet, may cause it to peel off the magnet under its own
weight during handling operations. A number of magnets may be selected to give
greater coverage over the load area rather than reliance being placed on weight-lifting
ability alone. Proper configuration/positioning of the magnets should minimise the sag or
droop of the overhanging portions of a load.
 Nature of the lifting operation – If the load is not balanced and hanging level, or the
operation requires the load to be tilted, slippage may occur unless the adhesive force
generates sufficient friction to resist it.

27. Magnetic Lifting Accessories
 Surface condition of load and magnet - The effectiveness of a magnet falls rapidly
as the distance between its face and the load i.e. the air-gap, is increased. Good
contact between the surfaces of the magnet and the load is essential for the magnet
to achieve optimum and safe performance. To maximise contact, both the magnet
face and the load surface should be as smooth and clean as possible and the air-gap
kept to a minimum. The surface texture or finish of the load and the presence of paint
rust, oxide scale, oil, ice and snow etc and non-magnetic material on either surface
will increase the air-gap, thus reducing the contact and, possibly, the magnetic
effectiveness.
 Temperature of load and magnet - The temperature of the magnet and load should
be taken into account as, for example, ferrous materials lose their magnetic
properties with increasing temperature and cease to be magnetic at around 700oC.
Magnets should not be used for hot work unless specially designed for this duty, and
then only within the specified operating temperature limits

28. Safe Working Load And Working Load Limit
• SWL (if the term is going to be used) can now be thought of as a de-
rating of WLL, following an assessment by a competent person of the
maximum load the item can sustain under the conditions in which
the item is being used.
• ISO Standards clearly state they now want WLL to be defined as:
• The maximum load that an item can lift
• The maximum load that an item can lift in a particular configuration
or application.
• This information will be stamped or marked on all equipment
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29. Chain Information
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30. Chain Use and Condition

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DIRECT VERTICAL
LIFT ONLY
IN WORK UP TO SHOULDER
NOT PACKED OUT
CORRECT THREAD TYPE
NO SIDE PULLS
VISUAL INSPECTION
PLANT No. & SWL
DYNAMO EYEBOLTS

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VERTICAL OR ANGLE
LIFT
ALWAYS USE A SHACKLE
ANGLE UP TO 45= 1/4 SWL
PULL OUT OF SIDE NOT BACK
VISUAL INSPECTION
PLANT No. AND SWL
COLLAR EYEBOLTS

33. HOIST RINGS
• Can be used in place of
eyebolts and depending on
the design may not always
need reducing when lifting
at angles.
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»PIN FITS ON HOOK
»PULL IN 1 DIRECTION ONLY
»PLANT No. & SWL
»VISUAL INSPECTION

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•PIN FITS ON HOOK
•VISUAL INSPECTION
•PLANT No. & SWL
•CAN PULL 2 DIRECTIONS

36. 36
MUST BE MARKED WITH SAFE
WORKING LOAD & PLANT ID NUMBER
SWL MAY BE STRAIGHT LEGGED (NOT
WITH INCLUDED ANGLE OR STATE THE
INCLUDED ANGLE)
INCLUDED ANGLE IS CRITICAL

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•AVOID STRONG CHEMICALS
•AVOID ULTRA-VIOLET LIGHT
•AVOID EXTREMES OF TEMPERATURE
•DO NOT FORCE DRY
•DO NOT TIE KNOTS
•DO NOT USE IF DAMAGED
•DO NOT DRAG ON FLOOR

38. Lifting Accessories
• Check For Damage
• Information Available
• I.D. Number
• Safe Working Load
• Usage
• Included Angle

39. Types of Damage

40. Crane Maintenance And Pre-Use Checks
Crane maintenance should be carried out as per manufactures
schedule and includes things such as checking security of the chain
bags and ensuring correct and safe operation.
Pre-Use checks…
 Limit Switch Up
 Limit Switch Down
 Travel
 Traverse
 Stop Button
 Speed Control
 Isolator

41. Planning Your Job• What should you do before moving a load?
• Make sure you have the required training for the particular job
• Make sure the crane is suitable to lift and travel the load.
• Make sure the job site is planned and laid out
• Check ground conditions to ensure stability.
• Visually inspect the crane before use.
• Make sure all loose materials, parts, blocking and packing have been
removed from the load before lifting.
• Remove any slack from the sling and hoisting ropes before lifting the load.
• Make sure that the lifting device seats in the saddle of the hook.
• Verify that the load is not heavier than the maximum load capacity.

42. Planning Your Job
• How should you move loads safely?
• Determine the size, condition, weight and centre of gravity
• Move crane controls smoothly. Avoid abrupt, jerky movements of the load.
At a consistent height.
• Follow signals only from one slinger in charge of the lift, except a stop signal.
• Make sure everyone is away from the load before hoisting.
• Make sure all slings, hooks, hardware, etc. are appropriate for the load being
lifted, are in good working order, and that all angles for the slings are
appropriate.
• Lift the load a small amount to verify that the braking system is functioning
properly before proceeding with the lift.

43. Planning Your Job
• What should you do before leaving the crane?
• Remove the load hanging on crane hooks.
• Raise all hooks to a safe position.
• Spot the crane at a designated location.
• Before closing the main switch, make sure that all controllers are in the "off"
position.
• Activate emergency stop
• Check chain and pendant support in good order

44. Emergency Stop Signal
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45. What Now
 This training will have given you a better understanding of how to use cranes in a safe manner and what procedures
are in place to keep you safe!
 Thank you for taking the time to complete this Training.
 ANY QUESTIONS??